Method and apparatus to produce artificial teeth for dentures

ABSTRACT

This invention pertains to a method and apparatus to fabricate economical full arch unitary upper and lower sets of artificial teeth for use in preparing dentures for edentulous dental patients and attaching said sets of teeth to denture base material by a process developed for the purpose of utilizing these sets of teeth and converting them into finished upper and lower dentures by the use of a specialized apparatus. The process and apparatus, per se, are the subject of another related application and eliminates the conventional procedure of mounting individual artificial teeth in the normal process of fabricating dentures.

BACKGROUND OF THE INVENTION

The production of artificial dentures is an art which has existed for atleast several hundred years and over that period has constantly beenimproved to achieve the ultimate goal of maximum comfort to personswearing such dentures and close simulation to natural dentitions. One ofthe principal difficulties involved in the preparation of artificialdentures comprises the arranging of artificial teeth and connecting thesame to denture base material to produce finished dentures. The majorityof dentures made at the present time include the connection ofindividual artificial teeth to the denture base material and this isaccomplished, in the main, by dental laboratories, but is by no meansrestricted to the same in that some dentists prefer to fabricate thedentures for their patients.

In general, the preparation of full dentures commences with takingimpressions of both upper and lower edentulous arches, and establishingtheir relative position to one another both at rest and in function.These methods are described in texts and other publications, and resultgenerally in the preparation of a "bite record" used by the dentallaboratory from which a try-in is fashioned.

The impressions are taken by procedures well known to the art usingalginate impression material or the like, and models of the patient'sjaws and gums, known as casts are formed from setable materials such ascertain gypsum material, commonly referred to as "dental stone". Abaseplate next is formed upon the cast using a thermoplastic material insheet form, by softening and adapting it over the cast. Upper and lowerbaseplates prepared in this manner are then used by the dentist toestablish a bite record. The baseplates are introduced into the mouth ofthe patient, separated by soft wax which is deformed by the action ofthe patient's jaws as they are guided into their proper position by thedentist. The soft wax is modeled in a relatively rough labial contour ofthe teeth as they will be positioned in the finished denture, and therelationship between the jaws is transferred to a dental articulatorwhich serves to hold the casts in the same relative position, asdescribed in greater detail hereinafter. Also, certain measurements madewith appropriate instruments determine the preferred vertical relationespecially between the central, forward portions of a patient's gums onthe respective jaws, known professionally as the "incisive papilla".

Individual posterior and anterior artificial teeth then are imbedded inwax material, known as "set-up wax," applied to the baseplates toconform to the surfaces determined by the "bite record." Then additionalwax is applied between the gingival surfaces of the artificial teeth andthe baseplates in a manner to resemble natural gum contours. Theforegoing operations are performed while the casts are mounted in theupper and lower bows or members of an articulator which permits relativemovement between the upper and lower sets of artificial teeth formed onthe casts by the foregoing procedures and thereby enables a dentaltechnician or dentist to provide desirable occlusion and functionbetween the artificial teeth on the respective casts. Mounting suchteeth on the cast or model by the foregoing procedure requires extensiveskill and is relatively time-consuming. The elimination of suchsubstantial consumption of time is an essential objective of the presentinvention.

After the above procedures have been completed, the baseplates and thecontoured wax material and artificial teeth mounted thereon then areremoved from the articulator respectively and may be tried in the mouthof the patient, if desired. With the upper and lower casts attachedthereto, they are then invested in suitable molding compounds, generallyof a gypsum nature. The baseplate and set-up wax are removed from thehardened investment by heating and softening methods to provide a cavityinto which permanent denture base material is injected or molded forconnection to the ridgelap and gingival surfaces of the artificial teethby the well-known "lost wax" process.

The foregoing procedure is generally exemplary of the methods used atpresent to fabricate artificial dentures. Various modified steps of theprocedure occur at present, but in general, it will be seen that one ofthe principal difficulties arising from the procedure comprises themounting of individual artificial teeth upon the wax substrate to whichthey are attached and also to provide proper occlusion between theopposed masticating surfaces of the teeth in the upper and lowerdentures.

One of the improvements offered by the present invention in at least oneprincipal aspect comprises the use of full arch upper and lower sets ofartificial teeth which are integrally connected together in said setsand opposite sides of each arch formation are braced to stabilize theshape. The teeth provided in said full arch sets have certaincharacteristics which attempt to resemble natural teeth, while at thesame time, facilitating the molding of such teeth in molds whichpreferably are relatively simple. In this regard, it is to be noted thatthe use of full arch sets of artificial teeth to form dentures is notnew from a basic standpoint. Previous attempts to simplify the formationof artificial dentures have included the use of such full arch sets ofartificial teeth and typical examples of the same are found in suchprior U.S. Patents as U.S. Pat. No. 1,814,717 to Maizner, dated July 14,1931; U.S. Pat. No. 2,539,882 to Zilinski, dated Jan. 30, 1951; U.S.Pat. No. 2,768,440 to Elliott, dated Oct. 30, 1956; and U.S. Pat. No.4,099,329 to Hawthorne, dated July 11, 1978.

In addition to the use of full arch sets of artificial teeth in themaking of dentures as noted above, various procedures for the forming ofdentures with the aid of articulators in order to attempt to minimizethe amount of time consumed have been the subject matter of other priorU.S. Patents, including U.S. Pat. No. 1,814,717 to Maizner, dated July14, 1931; U.S. Pat. No. 2,171,759 to Meyer, dated Sept. 5, 1939; andU.S. Pat. No. 4,189,837 to Stele, dated Feb. 26, 1980, as well as priorBritish Pat. No. 295,768 to Perks, dated Aug. 23, 1928 and prior GermanPat. No. 508,921 to Kantorowicz, dated Oct. 2, 1930.

Further to facilitate the formation of artificial teeth with an enamelsimulating layer, prior U.S. Pat. No. 1,547,643 to Clapp, dated July 28,1925, illustrates a form of mold and technique to accomplish this, whileprior U.S. Pat. No. 1,907,923 to Willis, dated May 9, 1933, is oneexample of a measuring device used incidental to determining desirablebite level between artificial dentures and thereby facilitate thecomfort of using the same.

The characteristics and advantages of the present invention over thetechniques and apparatus presently in use, as enumerated above, are setforth below in detail.

SUMMARY OF THE INVENTION

It is among the objects of the present invention to improve and simplifythe technique of forming artificial dentures primarily by using fullarch sets of artificial teeth and employing a process by which saidteeth ultimately are fabricated as finished dentures by the employmentof procedural steps and apparatus submitted to be improvements over theprocedures and apparatus presently in use, both as enumerated above andas practiced presently by dentists and dental technicians in dentallaboratories.

The full arch unitary sets of artificial teeth comprising an importantand advantageous feature of the present invention, are the subject ofthe present application, the teeth in the anterior portion of the setsin particular being provided with interproximal spaces adjacent thegingival portions of the teeth for purposes of permitting denture basematerial to be positioned between the gingival areas and thus, resemblenatural gums, and in regard to both the anterior and posterior teeth,the labial and buccal surfaces thereof have been formed to resemble thecorresponding surfaces of natural teeth insofar as possible, but saidsurfaces have been shaped in a manner to readily permit the removal ofthe molded full arch sets of teeth from rigid molds without interferenceand with minimum requirements for finishing.

Ancillary to the foregoing object relative to the full arch sets ofartificial teeth, the same are provided with stabilizing strut meansextending between and connected to opposite sides of the U-shapedconfiguration of said full arch sets, the strut means comprising fingersextending radially from a central member and the ends of the fingerswhich are connected to certain of the posterior teeth are of minimalcross-sectional area to facilitate separating the same from the fullarch sets of teeth prior to the final contouring of the lingual surfacesof the posterior teeth, as forth in detail hereinafter.

In performing the preferred process for forming dentures which includethe full arch sets of teeth of the present invention, a number ofapparatus units have been developed, together with the steps of thepreferred procedures, all of which are the subject matter of anotherrelated application. However, to appreciate the significant novelty andadvantages afforded by the use of the full arch artificial teeth of thepresent invention and for convenience, a relatively full description ofthe apparatus and process is included hereinafter in the presentapplication.

Details of the foregoing objects and of the invention, as well as otherobjects thereof, are set forth in the following specification andillustrated in the accompanying drawings comprising a part thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of an exemplary full arch unitary set of upperartificial teeth, embodying the principles of the present invention.

FIG. 2 is a sectional view taken on the line 2--2 of FIG. 1 and showingthe cross-section of a central tooth of the set of full arch teeth,shown in FIG. 1, the labial face of the tooth sloping in at the gingivaland out at the incisal, to facilitate removing the teeth from a rigidmold.

FIG. 2a is a view corresponding to FIG. 2, but showing thecross-sectional shape of a normal central artificial tooth in which thelabial face of the tooth extends inwardly at the incisal, which wouldimpair the removal of the tooth from the type of mold preferred tomanufacture the teeth of the present invention.

FIG. 3 is a vertical sectional view of a canine tooth of the set shownin FIG. 1, as seen on the line 3--3 thereof, and illustrating as inregard to FIG. 2, the manner in which the canine tooth slopes inwardlyat the gingival and outwardly at the incisal to facilitate the removalof the same from the mold.

FIG. 3a is a view similar to FIG. 3, but shows a sectional view of amore or less conventional canine artificial tooth in which the labialsurface extends inwardly at the incisal, as well as at the gingival.

FIG. 4 is a sectional view of a posterior tooth formed in accordancewith the invention, as seen on the line 4--4 of FIG. 1, and illustratinglabial surfaces which slope inwardly from the gingival toward theocclusal.

FIG. 4a illustrates a similar cross-sectional shape of a conventionalposterior artificial tooth in which the labial surface thereof issubstantially perpendicular to the occlusal plane illustrated by thebottom horizontal phantom line.

FIG. 5 is a plan view of the occlusal surface of the exemplary full archset of artificial teeth shown in FIG. 1.

FIG. 6 is a front elevation of the full arch set of artificial upperteeth shown in FIG. 1.

FIG. 7 is a side elevation of an exemplary full arch set of upper andlower artificial teeth, including employed in details the presentinvention and shown in occlusion with respect to each other, said viewshowing in particular the sloping labial surfaces of the central teethof the respective sets thereof, which correspond generally to FIG. 2.

FIG. 8 is a front elevation of an exemplary full arch set of lowerartificial teeth and illustrating as in FIG. 6 the indentedinterproximal surfaces adjacent the gingival ends of the teeth.

FIG. 9 is a vertical sectional view of an exemplary set of upper andlower dies in which full arch sets of upper and lower artificial teethare capable of being molded to have the general characteristicsespecially shown in FIGS. 6-8.

FIG. 10 is a top plan view of an articulator of a simplified type foruse in the process preferred for incorporating sets of teeth of thepresent invention in finished dentures.

FIG. 11 is a side elevation of the articulator shown in FIG. 10, asviewed from the right-hand side thereof, shown in said figure, FIG. 11also including fragmentarily in phantom, an elevated position of theupper bow of the articulator.

FIG. 12 is a fragmentary vertically sectioned detail of the pivotalsupport for the upper bow, as seen on the line 12--12 of FIG. 10.

FIG. 13 is another horizontal sectional view, showing a detail of saidpivotal means for the upper bow, as seen on the line 13--13 of FIG. 11.

FIG. 14 is a fragmentary vertical sectional view showing details for thesupport means of the mounting table, shown on the line 14--14 of FIG.11.

FIG. 15 is a fragmentary horizontal sectional view of the support meansshown in 14, but as seen on the line 15--15 of FIG. 11.

FIGS. 16, 17, and 18 respectively show top, side, and bottom views ofthe support table shown in FIG. 11.

FIG. 19 is a side elevation of a measuring instrument useful inconjunction with the present invention, as shown in the fragmentaryportion of a human mouth, illustrated in phantom.

FIG. 20 is a front elevation of the instrument shown in FIG. 19.

FIG. 21 is a transverse sectional view of the instrument shown in FIG.20, as seen on the line 21--21 thereof.

FIG. 22 is a composite side elevational view of a pair of steppedwedge-like support members used in conjunction with levelling an uppercast with respect to the support table and being disposed between saidtable and the forward portion of the upper cast selectively inincrements of one millimeter.

FIG. 23 is a top plan view of one of the wedge-like members shown inFIG. 22.

FIG. 24 and 25 respectively are respective views of different types ofalternate support means used in articulators not illustrated in theforegoing views, in lieu of the supporting table actually shown in saidviews.

FIG. 26 is a side elevation of an exemplary upper gum or jaw of apatient and comprises a dental cast thereof.

FIG. 27 is a perspective view of an exemplary lower cast simulating thelower jaw of a patient.

FIG. 28 is a side view of the upper and lower casts of FIGS. 26 and 27,being joined in operative relationship by means of a jaw-relation biterecord, the elements shown respectively in FIGS. 26-28 normally beingsupplied by a dentist for purposes of utilizing the present invention.

FIG. 29 is a view similar to FIG. 19 and showing the instrument of FIGS.19 and 20 respectively engaging the lower end of the upper lip and theforward portion of the upper jaw or gum of a patient to provide arequired measurement incident to the use of the wedge member shown inFIGS. 22 and 23.

FIGS. 30-41 successively illustrate various steps of a preferred methodfor incorporating the full arch sets of upper and lower artificial teethof the invention into finished dentures, said steps being described indetail hereinafter in the specification.

FIG. 42 is a perspective view of an exemplary set of artificial upperand lower dentures in which full arch sets of the teeth of the presentinvention are included.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention includes a number of related facets all leading tothe common goal of producing satisfactory, reasonably life-likeartificial dentures which include full arch unitary upper and lower setsof artificial teeth, thereby resulting primarily in a substantial savingin time to produce the so-called dental "set-ups" which, as such, arethen processed by conventional methods or otherwise into finisheddentures. In the foregoing, reference has been made to the great skilland amount of time required to place individual artificial teeth onbaseplates with wax which is sculptured to provide aestheticconfigurations resembling natural gums, and it is in this area of theproduction of artificial dentures that the present invention providesvery substantial advantages.

As is evident from the prior art referred to hereinabove, the use offull arch sets of artificial teeth is not new per se. Attempts have beenmade by others to commercialize full arch sets of molded artificialteeth, but for the most part, these have been unsuccessful. Possibly amajor reason such prior commercial attempts have not been successful hasbeen due to an inability to produce such teeth economically, whileretaining acceptable aesthetics with practical adaptability to dentallaboratory utilization. The present invention has overcome thisdifficulty in what is submitted to be a practical and aestheticallyacceptable product.

One of the advantageous features of the sets of teeth of the presentinvention comprises the repositioning of many of the teeth from theangles normally chosen for a tooth arrangement for artificial denturesso that the teeth can be mass-produced in rigid molds without formationof objectionable parting lines. This has involved reshaping the teeth tomaintain a pleasing aesthetic appearance, as well as realigning them.The anterior teeth, including the central and lateral incisors, forexample, have the facial or labial surfaces thereof slanting outward atthe incisal edges so the same can be withdrawn from a rigid mold withoutleaving a parting line on such labial surfaces. The posterior teeth havetheir facial or buccal surfaces slanting inward toward the occlusalsurfaces so they may be withdrawn from another area of the molds withoutleaving a parting line. The canines are treated in an unusual way byslanting their facial or labial surfaces outwardly at the incisal edgesin line with the other anterior teeth, as will now be described indetail relative to the drawings.

FULL ARCH SETS OF ARTIFICIAL TEETH

Referring to FIG. 1, an exemplary full arch set of artificial teeth isillustrated in top plan view and shows the ridgelap depressions 12 ofthe four posterior teeth 14 at opposite sides of the set 10, and includefirst and second molars and first and second bicuspids, together withthe six anterior teeth at the intermediate portion of the archconfiguration and comprising a pair of central teeth 16, a pair oflateral teeth 18, and a pair of canines 20, all arranged to be moldedintegrally in rigid molds, such as illustrated in exemplary manner inFIG. 9, and comprising a rigid upper mold 22 and a matching lower mold24, details of which are described to a greater extent below.

To maintain the arched configuration of the exemplary set of upper teeth10, stabilizing strut means are attached to the inner surfacesespecially of the posterior teeth and comprise a central member 26 fromwhich radial fingers 28 extend somewhat in octopus manner. It will benoted the fingers 28 taper outwardly from the central member 26, thesmaller ends of the fingers being connected to the posterior teeth in amanner that may be readily severed therefrom after the stabilizingfunction of the strut means has ceased, such as when the full archconfiguration of teeth has been attached to baseplates or other meansdescribed hereinafter in detail.

To provide illustrations of the manner in which the present inventionhas effected repositioning of many of the teeth from angles normallychosen for a tooth arrangement for an artificial denture, attention isdirected to FIG. 2, which is a cross-section taken on the line 2--2 ofFIG. 1 and illustrates a vertical section of a central tooth 16, havinga ridgelap depression 12 and the facial or labial surface 30 sloping orslanting outward at the incisal edge 32 from the gingival end 34 tofacilitate withdrawing the molded teeth from a rigid mold, such asillustrated in exemplary manner in FIG. 9 with respect to the lower mold24 wherein the molding recess 36 forms the gingival end 34 of thecentral teeth 16, for example, and in which the surface 38, comprising aseries of adjacent molding cavities, forms the labial faces 30 of thecentral teeth. Preferably, the molding cavities 40 and 41 respectivelyin the lower and upper molds have parting lines at the incisal ends ofthe anterior teeth and occlusal surfaces of the posterior teeth.

From FIG. 2, it also will be seen that the labial surface 30 of centraltooth 16 slopes backward from the incisal end, away from the verticalreference line shown in phantom, at an angle of about 0° to 10° for atleast about 70 percent of the length thereof.

An exemplary illustration of a substantially conventional artificialcentral tooth 16' is shown in FIG. 2a and, as shown in FIG. 2, thelabial surface 30' thereof is illustrated with reference to ordinatephantom lines at right angles to each other, the vertical line being thereference line with respect to the slanting or sloping of the labialsurfaces of the teeth. In FIG. 2a, it will be seen that the labialsurface 30' of a central tooth slopes inwardly at both the gingival andincisal ends and would present difficulties in utilizing a single pairof rigid molds in which the parting line is at the incisal ends of theteeth, whereby the exemplary tooth shown in FIG. 2a could not bewithdrawn from molds of the type employed to form the exemplary centraltooth 16 shown in FIG. 2.

With reference to FIGS. 3 and 3a, it will be seen that in FIG. 3, takenon the line 3--3 of FIG. 1, a canine or so-called "eye tooth" 20 isshown, in which the facial or labial surface 42 slopes outwardly at theincisal end 44 and inwardly at the gingival 46, thus facilitating themolding thereof by rigid molds, as described above with respect to thecentral tooth 16, shown in FIG. 2. In contrast, the conventional caninetooth 20', shown in FIG. 3a, has an outward or labial surface of curvedconfiguration extending inwardly both at the incisal 44 and gingival 46and would similarly present difficulties in the type of rigid moldsemployed in the invention as described above with respect to FIG. 2a.With respect to labial surface 42, it will be seen from FIG. 3 that thesame slopes backward from the incisal end, away from the verticalreference line shown in phantom, at an angle of about 0° to 10° for atleast 70 percent of the length thereof.

Considering the posterior teeth 14 by referring to FIG. 4, which istaken on the line 4--4 of FIG. 1, it will be seen that the outer orbuccal surface 48 slopes outwardly at the gingival 50 of posterior tooth14 and inwardly at the occlusal end 52 to facilitate the removal fromthe molds 22 and 24, and especially the mold 22 and in which the moldsection 54 forms the occlusal surface 52 of the posterior teeth 14. Theabove-described slope of the buccal surface 48 in FIG. 4 is illustratedwith reference to an exemplary phantom ordinate line to illustrate thesloping arrangement. The ordinate line also is illustrative of a planarmember which, when laid against the buccal surface, will show that thebuccal surface slopes away from said member at an angle of about 0° to10° for about 90 percent of the height of the posterior tooth. Incontrast, referring to FIG. 4a in which a conventional similar posteriortooth 14' is shown, it will be seen that the conventional buccal surface48' slopes inwardly somewhat at the gingival end 50 and substantiallyinward at the outer portion of the occlusal surface 52, whicharrangement would present difficulties in utilizing molds of the typeshown in FIG. 9.

FIG. 5 is an exemplary bottom plan view of a full arch set of upperartificial teeth to illustrate the occlusal and incisal ends of theposterior and anterior teeth, said view being the opposite of that shownin FIG. 1. Referring to Fig. 6, which is a front elevation of theexemplary full arch set of upper artificial teeth, shown in FIGS. 1 and5, it will be seen in this view that the slope of the buccal surfaces ofthe posterior teeth 14 is well illustrated and it is to be understoodthat the shape, and especially the outer labial surfaces of the lateralteeth 18 is substantially similar to that of the canine or cuspid teeth20. Another important feature of the full arch set of artificial teethwhich adapts its use with the invention is also illustrated in FIG. 6 inwhich it will be seen that pronounced interproximal triangular spaces 56are illustrated for purposes of effecting desirable aesthetic contoursto cause these artificial teeth to closely resemble similar surfaces ofnatural teeth, at least portions of said interproximal spaces 56, aswell as the gingival end portion of the anterior teeth being partiallycovered by portions of the denture base material in the finisheddentures in a manner to resemble natural gums and teeth.

Referring to FIG. 7, it will be seen that there is illustrated therein afull arch set of upper artificial teeth 10 and a full arch set of lowerartificial teeth 58, both shown in side elevation and disposed inoperative relationship with respect to each other along an occlusalplane 60, shown in phantom. Preferably, the incisal edges of theanterior teeth which are shown at the left-hand end of FIG. 7, and theocclusal surfaces of the posterior teeth shown in the right-hand portionof FIG. 7, commonly abut the occlusal plane 60 and, while the teeth ofboth types are shaped to closely resemble the outer labial surfaces ofthe anterior teeth and the outer buccal surfaces of the posterior teeth,the occlusal surfaces of the posterior teeth, in particular, preferablyare of the so-called flat plane type in that the occlusal surfaces donot interdigitate.

Referring to FIG. 8, in which a front elevation of the full set ofartificial lower teeth 58 is illustrated, it will be seen that thecorresponding central teeth 62, lateral teeth 64, and canine or cuspidteeth 66 are respectively somewhat narrower than the corresponding teethof the upper set 10, as shown, for example, in FIG. 6, therebyharmonizing with this characteristic of natural teeth. The groups offour posterior teeth 68, however, as seen from FIG. 7, are not narrowerthan the corresponding teeth of the upper set 10. In particular,however, it will be seen that interproximal spaces 56 are provided inthe lower set of teeth 58 for the same purposes as described above withrespect to the corresponding interproximal surfaces of the upper set ofteeth 10.

For purposes of simplifying the molding of full arch sets of artificialteeth, it is preferred, in accordance with the invention, that arelatively simple set of cooperating upper and lower molds 22 and 24 beemployed. However, it is readily possible to use so-called 3-part molds,embodying principles of the type shown in the prior U.S. Pat. No.1,547,643 to Clapp, dated July 28, 1925, and in which there is shown aso-called shader mold which is used for purposes of including on thelabial or front surfaces of the anterior teeth, a thin layer of moretransparent plastic material than that with which the main body of eachtooth is formed for purposes of simulating more closely natural teethwhich have an outer layer of more transparent enamel over an opaque bodyof the tooth, and to this end, the exemplary molds shown in FIG. 9 maybe supplemented by a suitable third, shader mold.

For a complete understanding of the preferred procedure for using thesets of full arch teeth incident to preparing finished dentures, specialapparatus and procedures which have been developed and comprise thesubject matter of a separate related application, are included in thisapplication as follows:

For purposes of fabricating the above-described full arch sets ofartificial teeth into finished dentures, a special and very simplifiedtype of articulator has been developed, details of which are shown inFIGS. 10-13. Referring especially to FIGS. 10 and 11, the articulatorcomprises a lower bow or base member 70, which may be disposed upon anysuitable supporting surface, such as a counter or bench. It is generallytriangular in shape, as seen in FIG. 10, and has a central, somewhattriangular opening 72 formed therein and a securing pin 74 removablyextends through aligned openings in the portions of the base 70, whichare on either side of the central opening 72, this apparatus being usedin conjunction with securing the lower cast or model 76 of a patient'smouth to the base, one exemplary illustration of the same being shown inFIGS. 27 and 28.

Extending upwardly from the rear portion of the base 70, at oppositesides thereof, is a pair of support members 78, such as shown in FIGS.11-15. Said support members have rearwardly extending wing-likeextensions 80 and bracing fillets 82, shown in FIGS. 10 and 11,connected to a transverse support bar 84, which is integrally connectedat its ends to support members 78, as best shown in FIG. 14. The purposeof the bar 84 is set forth below.

Hingedly connected to the upper ends of support members 78 is an upperbow or member 86 which also has a somewhat triangularly shaped opening88, formed somewhat centrally thereof and another securing pin 90extends transversely through aligned openings extending transverselythrough opposite side portions of the upper bow at either side of theopening 88. The arrangement just described is for purposes of securingto the upper bow 86 an upper cast or model 92 of a patient, oneparticular example of which is shown in FIGS. 26 and 28. In FIG. 11, theupper bow 86 is shown in full lines in its normal operative position,while in phantom, the same is shown in elevated position. A post 94 ismounted for vertical adjustment within an opening in the forward portionof upper bow or member 86 as clearly shown in FIGS. 10 and 11,adjustment being secured by a thumb screw 96, and is operable tomaintain the upper bow 86 in normal substantially horizontal positionwhich is parallel to the base 70. An upper extension 98 is connectedaxially to the post 94 and is for purposes of holding the upper bow infull-extended, pivotal position, such as shown, for example, in FIGS.30-36. Similarly, the triangular shape of the extensions 80 on thesupport members 78 has a lower rearward edge surface 100, by which thearticulator may be supported when the surfaces 100 are disposed on asupporting surface, for any desired purpose.

Although the articulator shown in FIGS. 10-13 is of a very simplenature, especially as compared to other more sophisticated articulatorswhich in particular frequently have elaborate adjustable pivot means,the pivot means of the instant articulator permit at least a limitedamount of anterior, posterior, and opposite lateral movements of theupper bow or member with respect to the centric position to permit adesirable amount of milling movements between sets of full archartificial teeth when respectively supported by the upper bow 86 andbase 70, as described in detail hereinafter, as well as pivotal movementof the bows about a horizontal axis. Such limited milling movement ispermitted by details shown particularly in FIGS. 12 and 13, and in whichthe upper ends of the support members 78 are each provided with athreaded opening 102 to receive intermediate threaded portions ofthreaded thumb screws 104, having knurled knobs 106 on the outer endsthereof and the opposite ends of said screws having a smooth,cylindrical pivot extension 108 of less diameter than the threadedportion 104. Opposite sides of the rear end portion of the upper bow 86have short elongated recesses 110 of limited length and depth withinwhich the pivot extensions 108 are disposed.

The inner ends of the recesses 110 have a central socket 112, also oflimited depth, extending axially inwardly a limited amount for purposesof receiving the terminal end of the pivot extensions 108 when the thumbscrews 104 are threaded to the full permitted extent inwardly, whereby asolely pivotal movement about a transverse axis is afforded the upperbow without milling movement. However, by backing off the thumb screws104 sufficiently until the ends of the extensions 108 are disposed onlyin the short recesses 110, said limited amount of milling movement ofthe upper bow with respect to the base or lower bow may be effected, ascan be visualized from the length of the recess 110, shown in FIGS. 12and 13. This amount of movement is adequate to effect a highly usefuland practical milling movement.

An important element of the articulator comprises a mounting table 114which is planar and preferably triangular in shape as shown in FIGS. 16and 18. One surface of the mounting table 114 is provided with amounting bar or rib 116, which is parallel to the rear edge 118 ofmounting table 114 and is disposed a limited distance therefrom forpurposes of having the hamular notches 120 of the upper cast 92, seeFIG. 26, positioned thereon to facilitate the alignment and height ofsaid cast with the mounting table 114.

This situation requires the use of a measurement to facilitate the fullpositioning of the upper cast or model on said table and wedge blocks122, see FIG. 22, effect such positioning. Said blocks have steppedfaces arranged predetermined distances apart in elevation, in even orodd increments of two millimeters apart, and in view of there being apair of such wedges respectively with the stepped surfaces, one hassurfaces offset one millimeter with respect to steps on the other, andthereby selectively provide, for example, one millimeter adjustments inthe stepped surfaces while using one or the other of the wedge blocks122, such use being illustrated and described hereinafter relative toadditional figures.

The aforementioned measurement referred to immediately above can beeffected by an instrument such as that illustrated in FIGS. 19-21 andcomprising an elongated bar 124 at the upper end of which a lateralblade 126 is formed, the bar accommodating a slide 128, which, at itsupper end, has another blade 130 extending laterally therefrom and aviewing opening 132 also being formed in said slide for purposes ofobservation of scale indicia 134 formed on one face of the bar 124, asclearly shown in the upper portion of FIG. 20. Referring to FIG. 19,there is fragmentarily illustrated therein, in phantom, a sectionaloutline of an upper lip 136 of a patient and the central forward portion138 of the gum of the upper jaw of a patient, which is known as theincisive papilla.

The distance between the lower edge of the upper lip and the incisivepapilla is measured on the scale 134 and is indicated by the referenceline 140 on the slide 128, and the reading opposite the reference lineindicates the distance the incisive papilla on the forward portion 138'of the upper cast, shown in FIG. 26, must be spaced from the uppersurface of the support table 114, as viewed in FIG. 11, and from whichthe support bar 116 extends perpendicularly. Such spacing isaccomplished by utilizing a selected stepped surface of one of the wedgeblocks 122 which corresponds to said measurement and results in apositioning of the upper cast on the support table, as shown in FIG. 30.

Hamular notches in the upper casts or models of a patient's upper jawhave been used heretofore incident to leveling the cast relative to abench top in a dental laboratory. As far as is known, however, suchnotches have not been used heretofore in conjunction with a positioningor support table. Also, while the aforementioned measurement between theincisive papilla of an upper cast or model and the lower edge of theupper lip of a patient has been used heretofore to establish a plane inthe anterior region of a cast, such measurement has not been used as faras known to position said incisive papilla of the cast relative to asupport table, especially in conjunction with the stated use of thehamular notches of the cast. Such an overall combination is believed tobe novel and highly effective to produce satisfactory artificialdentures by the further procedures described herein.

The mounting table 114 is detachably and reversibly positionable uponthe lower bow or base 70 of the articulator and the support members 78which are affixed to the rear edge of the base 70 at opposite sidesthereof by any suitable means, such as screws 142. When the table is tobe mounted as shown in FIG. 11, with the mounting bar 116 extendinguppermost, a reversible supporting pin 144 is threadably connected tothe forward end of the table by being threaded into a suitable hole tosupport the forward end upon base 70. The rearward portion of table 114rests upon transverse support bar 84, as shown fragmentarily in FIG. 14,and thereby supports the mounting bar 116 uppermost for disposition ofthe upper cast 92 thereon in the manner shown in FIG. 30. In order toprevent sidewise movement of the table with respect to the base 70,opposite sides of the rearward portion of the table 114 are providedwith notches 146, which receive lugs 148 formed on the inner surfaces ofthe support members 78. Said members also are provided with notches 150,see FIG. 14, through which the rear edge of the table 114 may passincident to disposing the notches 146 with respect to the lugs 148.

The table 114 is reversible in order that the planar surface 152 thereonmay be disposed uppermost, when, for example, the upper full arch set ofartificial teeth 10 is to be mounted operatively with respect to theupper cast or model 92 by procedures described hereinafter. Toaccomplish this, table 114 is removed from the position shown in FIG. 11and is reversed to dispose the mounting bar 116 in a depending position,such as shown, for example, in FIGS. 36-38, the supporting pin 144 beingunthreaded from the position shown on the table in FIG. 11, and isthreaded into the opposite surface of the table and thus, disposes thetable 114 in opposite parallel position with respect to the base 70 fromthat shown in FIG. 11.

DENTURE FORMING METHOD AND PROCESS

In the introductory portion of this specification, reference has beenmade to the formation of upper and lower casts or models 92 and 76which, conventionally, are formed by a dentist and used by the dentistor sent to a laboratory for formation of the dentures by the employmentof such casts or models. In addition, the dentist conventionallyprovides a jaw relation bite record 154, which consists of a plasticmaterial of certain wax compositions or the like and, after beingsoftened, is capable of being inserted into a patient's mouth betweenthe upper and lower jaws and especially the gum portions thereof toimpress said gums into the material and, after cooling to stabilize thebite record, forms at least a temporary relationship record to establishthe relative vertical positions of the natural jaws with respect to eachother and upon which artificial dentures are to be mounted so as to fitcomfortably and be operable to masticate food while being retainedsolely by suction or gravity upon the patient's gums.

It is obvious that natural teeth in human dentitions space the gumsvertically apart a predetermined distance, and it is preferable thatthis distance or one very close to it in measurement be used to spaceapart the upper and lower casts or models shown in FIG. 28 by means ofthe jaw relation bite record 154. Having been furnished either the upperand lower casts or impressions by which the casts may be formed, as wellas the jaw relation bite record, a dentist or technician is then inposition to proceed in accordance with the principles of this inventionto fabricate a set of upper and lower dentures which includerespectively full arch upper and lower sets of artificial teeth 10 and58, such as shown in FIG. 1-8, by means of the following steps,illustrated sequentially in FIGS. 29-41:

Having obtained the required vertical spacing between the incisivepapilla 138 and the lower edge of the upper lip 136, the upper cast ormodel 92 is mounted in the articulator, as shown in FIG. 30, in whichthe upper bow or member 86 has been pivotally moved 180° to theinoperative position shown in FIG. 30, and thereby enable the upper castor model 92 to be mounted upon the table 114, with the hamular notches120 positioned upon the support bar 116, and a selected stepped surfaceof the wedge block 122 has been placed upon the table 114 to support theincisive papilla the required distance from the upper surface of thetable, as determined by the measuring instrument of FIGS. 19-21, so asto establish the upper cast in a position to receive the full arch setof upper artificial teeth by the procedures subsequently described.

The next step is shown in FIG. 31, in which the upper bow has beenpivoted to operative position with respect to the table 114 by the upperbow being accurately positioned above base 70 by means of the post 94,whereupon settable attaching material 156, such as plaster, dentalstone, or other gypsum-like material is disposed within the opening 88of the upper bow so as to surround the pin 90 and be attached to thesurface 158 of upper cast 92. The material 156 will operatively cure ina short period of time, such as twenty minutes, more or less, followingwhich the steps shown in Fig. 32 take place, which comprises removingthe table 114 and wedge block 122, as well as pivoting the upper bow 86to inoperative position.

The foregoing step is followed by attaching the jaw relation bite record154 to the upper cast or model 92 and also attaching the lower cast 76to the bite record 154, as shown in FIG. 33. In this position, the lowercast 76 is in position to be attached to the base 70 of the articulatorby additional settable material 160 of the same type as material 156,and illustrated in FIG. 34. Usually, when applying the material 160 tothe base 70 and lower cast 76, the assembly shown in FIG. 33 is manuallyreversed while holding the upper bow 86 on base 70 in the relationshipshown in FIG. 33 so that the material 160 may be poured through theopening 72, see FIG. 11, of base 70 and into engagement with the surface162 of the lower cast and then permitting the material to set within theopening 72 and around the securing pin 74, which brings us to the stepshown in FIG. 35, in which the upper bow 86 is pivoted to inoperativeposition with the upper cast 92 is secured thereto. The bite record 154is removed from both casts and the lower cast 76 with its attachingmeans 160 is removed from the base 70.

The next step comprises replacing the mounting table 114 in reversedposition to that shown in FIG. 11, for example, as well as FIGS. 30 and31, in order to dispose the planar surface 152 of said table uppermost,as shown in FIG. 36, it being understood that the supporting pin 144also is reversed so as to engage base 70 and thereby support the planarsurface 152 in proper position as shown in FIG. 37 to receive a fullarch set of upper artificial teeth 10 with the incisal and occlusalsurfaces of the anterior and posterior teeth precisely upon the uppersurface 152 and in desired position with respect to the upper cast ormodel 92, as indicated by the spaced indicating lines 162 and medianline 164 inscribed upon the surface 152 of the table 114, as shown infull lines in Fig. 18.

The foregoing positioning of the upper set of teeth 10 is accomplishedby use of the upper cast or model 92 when supported by the upper bow ormember 86 as shown in FIG. 37, but before the teeth 10 are placed asshown. Chiefly by sighting, an imaginary perpendicular line is droppedfrom the incisive papilla of the upper cast or model 92 to the lines 162and centered on median line 164 and marked by pencil or otherwise. Thelines 162 preferably are spaced metrically and preferably at 1 to 4 mmspacing, most preferably 2 mm spacing. The mark then is moved forwardlyabout 4 or 6 mm to determine the location for the front anterior surfaceof the central teeth 16 of the upper set of teeth 10. With the set ofteeth held firmly in the latter position, such as shown in FIG. 37,attaching material 168, or other material referred to hereinafter, isapplied between the set of teeth and the upper cast or model 92 toconnect them together for further procedure.

Further to assist in such positioning of the full arch set of teeth 10upon the surface 152 of table 114, an adjustable positioning member 166,shown in exemplary manner in FIGS. 17 and 18, may be employed withrespect to the gradient lines 162 to have the foremost anterior portionof the full arch set of teeth 10 disposed against member 166 and therebyprevent movement of the teeth especially along the median line 164, forexample, and thereby accurately position the teeth for applyingremovable attaching material 168, such as soft sticky wax, between theteeth and the upper cast 92 upon which, in accordance with usualprocedure, a usually thin configuration of baseplate material, such aswax and/or plastic, or mixtures thereof, of conventional type, has beenshaped to conform to the gum surface of the cast but is readilyremovable therefrom and to which the attaching material 168 readilyadheres between the gingival portions of the full arch set of teeth 10and the baseplate, which is not shown in detail but is of conventionaltype as aforesaid.

Initially, small lumps of the attaching material 168 may be used asdescribed and ultimately, additional wax material is aestheticallyshaped upon the baseplate material on the gum portion of the cast 92, inorder to provide desirable contour surfaces extending upward from theteeth and resembling natural gums in the finished denture to be formedfrom the process being described.

Following the steps shown in FIG. 38, and referring to FIG. 39, it willbe seen that the next step comprises pivoting the upper bow 86 to theposition shown in FIG. 39, followed by removing the mounting table 114and replacing the lower cast 76 and its attaching material to the base70, whereupon the upper bow 86 is returned to the operative positionabove base 70. When the lower cast 76 is in the position shown withrespect to base 70 in FIG. 40, the full arch set of lower teeth 58 isplaced closely in occlusion relative to the full arch set of upper teeth10 so that they are in the proper relationship, such as shown inexemplary manner in FIG. 7, for example, whereupon the lower set ofteeth 58 is at least temporarily attached to the sheet-like baseplatematerial previously conformed to the lower cast 76 by means ofadditional lumps of removable attaching material 170, or otherwise, inorder to stabilize the set of lower teeth 58 with respect to the cast76. Thereafter, as described above in regard to the upper set of teeth10, an aesthetic application of additional wax or similar material isadded to the teeth and baseplate material to resemble natural gums,whereby the lower set of teeth and baseplate on the lower denture 76 arefinalized as to shape to resemble natural gums. Preferably, at thisstage of the process, the radial fingers 28 of the strut means aresevered from the full arch sets of the teeth, just prior to thefinishing the final contouring of the wax.

After the upper and lower sets of full arch artificial teeth have beensecured respectively to the baseplates upon the casts or models, both ofthe baseplate configurations with the artificial sets of teeth attachedthereto may be removed and fitted to the patient's gums for a try-in,and if necessary, desirable adjustments may be made.

In the foregoing, reference has been made to the adjustable positioningmember 166, shown in FIGS. 17 and 18. An exemplary type thereof is showntherein and may be made of metal or plastic and has a curved uprightflange which abuts the forward anterior portion of the upper full archset of teeth 10, especially to prevent forward movement thereof whileattaching the same to the baseplate on the gum portion of upper cast ormodel 92, as can be visualized from FIGS. 37 and 38, especially. Themember 166 is slotted to receive a thumb screw 161 which is threadedinto a hole in table 114 and after adjustment of the curved portionrelative to the indicating lines 162, the screw is tightened to securethe desired position of the member upon table 114.

After the finishing wax has been added between the respective sets offull arch teeth and the respective baseplates attached thereto so thatthe surface of the waxed-up products resemble the natural gums and teethdesired to be reproduced, the connected sets of teeth and baseplates areremoved with the casts or models to which they are removably attachedand then are processed in a conventional manner to produce the finisheddentures comprising the full arch sets of artificial teeth integrallyconnected to conventional denture base material which is inserted intothe molding cavities formed by the conventional processing methodsnormally employed for such purposes.

Such conventional methods include investing the waxed-up teeth andbaseplates and the upper and lower casts or models in so-called dentalstone or similar material mounted in flasks of well-known type, followedby boiling out the removable material of wax or otherwise while leavingthe artificial teeth, and especially the occlusal and incisal portionsthereof embedded in the dental stone, thereby forming the cavity of thedesired shape of the denture base to be attached to the teeth. Viscousdenture base material then is placed by conventional apparatus and meansinto such cavity for bonding to the ridgelap surfaces of the posteriorand anterior teeth and overlapping of some of the gingival surfaces ofsaid teeth, as well as a certain amount extending at least partiallyinto the interproximal areas 56 between adjacent teeth and clearlyillustrated in FIGS. 6-8, all resulting in the formation of imitationgums contoured to resemble natural gums and attachable to the gumportions of the upper and lower jaws of the patient and retainedthereagainst by suction and/or gravity, particularly in regard to thelower denture. See Fig. 42 for an exemplary illustration of suchdentures.

The completed dentures are removed from the dental stone comprising themolds into which the denture base material is injected, and aftersuitable polishing of conventional type, the completed dentures areready for try-ins and actual use.

Lastly, referring to FIG. 41, when the finished dentures are completed,it is sometimes found that a limited amount of milling between the upperand lower sets of teeth is desirable in order that the incisal andocclusal surfaces thereof may suitably occlude and thus dispose theteeth and especially the occlusal and incisal surfaces thereof as shownin FIG. 7, for example, along a common occlusal plane 60. To accomplishthis in accordance with the present invention, the knobs 106 of thethumb screws 104 are reversely screwed to back off the screwssufficiently to disengage the pivot extensions 108 from the centralsockets 112 to an extent such as shown in phantom in FIG. 13, whereuponthe pivot extensions 108 are disposed entirely within the short recesses110 and thereby permit limited lateral movement of the upper bow withrespect to the upper ends of the support members 78, as well as the base70, and thus permit milling between the incisal and occlusal surfaces ofthe sets of teeth 10 and 58 to a desired extent, such movement beingindicated in exemplary manner by the direction arrows 172 in FIG. 41.

Referring to FIG. 24, an exemplary substitute support 174 is shown foruse upon one type of a conventional articulator in the event it is notdesired to employ the articulator of the present invention and themounting table 114 thereof. The support 174 has a planar support surface176 and a mounting bar 178 for positioning hamular notches of the uppercasts. Vertically adjustable base members 180 at opposite sides permitadjustment of surface 176 relative to the lower bow or base of suchconventional articulator.

In FIG. 25, another attachment 182 is shown for use with anotherwell-known type of articulator and is provided with a mounting bar 184to be engaged by hamular notches of an upper dental cast.

From the foregoing, it will be seen that the above-described mechanicalelements and the full arch sets of upper and lower artificial teeth ofthis invention result in producing desirable and highly acceptableartificial dentures with a minimum of operational steps and especiallyin the saving of time over that required to individually mountartificial teeth in wax in accordance with normal procedures andespecially including interdigitation thereof, when necessary. Further,by utilizing pre-formed full arch sets of upper and lower artificialteeth, mismounting of the teeth and otherwise possibly misaligning thesame is avoided, compared to the possibility of mismounting andmisaligning that can occur when utilizing individual artificial teeth inthe preparation of dentures.

The foregoing description has referred to the preparation of thearrangement of conventional, removable wax and baseplate material andthe sets of full arch teeth attached thereto being processed intofinished dentures by conventional techniques such as investing the waxedmodels and full arch teeth in dental "stone" and "boiling out" theremovable wax and baseplate material to form a cavity into whichconventional denture base material is inserted for attachment to theteeth which are partially embedded in the dental "stone." The presentinvention is not to be restricted to the above-described techniques,however, in that further improvements also are included in the inventionwhich include the use of certain compositions comprising manually ormechanically applicable, actinic light-curable baseplate and denturebase material in lieu of removable wax and conventional baseplatematerials described above. These compositions may be quickly cured,thereby further to shorten the time required to form finished denturesin accordance with the following description.

One example of a composition that is moldable to a denture base form andis hardenable and cured by exposure to visible light was prepared fromthe following ingredients in the manner described hereinbelow:

    ______________________________________                                        PERCENT BY WEIGHT OF TOTAL COMPOSITION                                        ______________________________________                                        39.44   Urethane dimethacrylate (Reaction product of                                  hydroxyethyl methacrylate and 2,2,4-                                          trimethylhexyl-1,6-diisocyanate)                                      2.57    1,6-Hexanediol dimethacrylate (HDDMA)                                 0.13    Camphoroquinone (CQ)                                                  0.59    DMAEMA-MAA salt prepared as in Example 2                              42.10   poly (methyl methacrylate-co-ethylene                                         dimethacrylate 99.8:0.2) a polymer supplied by                                L. D. Caulk Company (Polymer is in                                            substantially spherical beads the shape                                       resulting from its suspension polymerization.                                 At least 50% by weight of the beads have                                      average diameters of less than 50 microns.                                    The polymer was prepared from methyl                                          methacrylate and ethylene dimethacrylate by                                   suspension polymerization*).                                          0.07    red acetate fibers                                                    0.03    pigments                                                              15.07   fumed silica inorganic filler (Aerosil R972 a                                 product of Degussa)                                                   ______________________________________                                         *The polymer was prepared according to the teaching of U.S. Serial No.        318,356, filed November 5, 1981, which was a Continuation of U.S. Serial      No. 008,507, filed February 1, 1977.                                     

First CQ was dissolved in HDDMA and then mixed with the amine salt andurethane dimethacrylate. The resulting liquid solution was charged to adouble planetary mixer heated to 45° C. and mixed under 20 mm Hgpressure. Next the polymer with the pigments and fibers previouslyblended in a V-Cone Blender was added and mixed under 20 mm pressure.The temperature was increased to 55° C. and the fumed silica was addedin three increments of about equal size and mixed under 130 mm pressureeach time. This produced a visible light curable (VLC) putty-paste.

By putty it is meant a viscous material that can be deformedmechanically (manually) and will at least temporarily hold the shapeinto which it has been deformed or molded.

The initial setup of the upper and lower stone models and determinationof the relative position of the upper full arch set of teeth in anacticulator was the same as previously described and illustrated withrespect to FIGS. 30 through 37. In this way, the dental models areprecisely positioned in space in a manner allowing their removal andreturn to precisely the same position. However, from that stage forwardthe process did differ in the manner now to be described.

The VLC putty was then treated to remove excess entrapped air by placingthe putty in a canister and subjecting it to a vacuum of 120 mm mercuryand then the vacuum was released and the putty was subjected to pressurein a hydraulic press. The putty was then extruded through Deldren Diesusing a ram extruder into a sheet having a size of 0.909 inch ×2 5/8inches and a rod having a diameter of 0.25 inch. The dental model wasremoved from the aforesaid precise position by opening the articulatorto the position shown in FIG. 36. The molding surface of the dentalmodel was provided with a coat of a release or separator system.

The separator system was a two part system:

(1) The first part of the system functioned as the gypsum mold or modelsealer. This first part was prepared from the following ingredients:

    ______________________________________                                        0.68%     Hydroxyethyl cellulose (Natrosol 250 HR,                                      Hercules, Inc.)                                                     97.82     Water                                                               0.30      Nonylphenyl ethoxylate surfactant (Makon                                      10, Stepan Chemical Company)                                        0.20      0.1% FD & C Blue #1 Dye in water                                    1.00      Preservative (Glydant, Glyco, Inc.)                                 ______________________________________                                    

The above ingredients were mixed together at ambient conditions and theresulting solution was a clear, blue colored solution with a viscosityof 354 centipoises at 22° C. (Brookfield Synchro-lectric Viscometer,model RVT, #2 Spindle, 100 rpm). This sealer was brushed over the entiregypsum model surface. The solution dried very quickly leaving an almostinvisible film on the surface. The model was removed from thearticulator for application of the sealer and then reset in thearticulator.

(2) Then, the second part of the separator system was brushed over thecoated surface, covering ONLY the areas to be in contact with VLCDenture Resin. The wet model was then dried under a hair dryer for fiveminutes. This second part of the separator system functioned as asurface cure promoter and was prepared from the following ingredients:

    ______________________________________                                        41.00%     Polyvinyl pyrrolidone (Plasdone K 29/32,                                      GAF Corporation)                                                   58.23      Water                                                              0.045      Silicone antifoam (SAG 471, Union                                             Carbide Corporation)                                               0.225      Surfactant (Makon 10, Stepan Chemical                                         Corporation)                                                       0.50       Sodium benzoate                                                    ______________________________________                                    

The above ingredients were mixed together at ambient temperature andpressure and the resulting solution was a very viscous clear yellowcolored liquid with a viscosity of 850 centipoises at 22° C. (#2spindle, 20 rpm).

A sheet of the previously described VLC putty, 3.5" long, was conformedto the desired shape on the upper dental model by pressing it into shapeby hand using the techniques employed in conventional denture baseplateshaping with wax. The sheet was thereby formed or molded into a denturebaseplate for the upper denture.

The baseplate was removed from the articulator and trimmed and thenhardened and cured for two minutes on a turntable rotating under four150 watt quartz-halogen lamps with a 400-500 nm band-pass filter. Theturntable was in the denture curing apparatus of U.S. Ser. No. 492,284,filed May 6, 1983, which is assigned to the same assignee as the presentpatent application, and this is the preferred apparatus although anyarrangement providing a good cure can be used and those skilled in theart can provide adequate cures in other manners. The light flux variedfrom 100-130 mw/cm² on the surface of the baseplate in the procedurecarried out.

A full arch set of upper teeth was prepared for attachment to the upperdenture baseplate by first roughening the ridgelap portion with a dentalbur to assure the very best bond and then coating the ridgelap with abonding agent to further assure an excellent bond. The bonding agent wasprepared from the following ingredients:

    ______________________________________                                        QM 657 (Rohm & Haas)   30.00 g                                                Methyl Methacrylate    30.00 g                                                Acrylic Acid            6.00 g                                                1,6-Hexanediol Dimethacrylate                                                                        10.00 g                                                Dimethylaminoneopentyl Acrylate-                                              Methacrylic Acid (DMANPA MAA)                                                                         1.56 g                                                Camphoroquinone (CQ)    0.30 g                                                Uvithane 782 (Morton-Thiokol)                                                                        63.00 g                                                ______________________________________                                    

The ingredients were mixed in an amber bottle at ambient conditions andthen heated at 60° C. until comletely homogeneous.

The VLC Tooth Bonding Agent was brushed on the area of the teeth to bebonded and allowed to stand for two minutes. Then, the VLC Tooth BondingAgent was light cured on the teeth by two minutes exposure, in themanner described for curing the VLC denture baseplate composition.

The reason the bonding agent is important as described is that the fullarch set of teeth is made from the currently preferred polymercomposition as taught in U.S. Ser. No. 318,351 filed Nov. 5, 1981 whichwas a continuation of U.S. Ser. No. 137,642 filed April 7, 1980, (nowabandoned) which was a division of U.S. Ser. No. 008,507 filed Feb. 1,1979 now abandoned, all of which are assigned to the assignee of thepresent application and the contents of which are incorporated in thisapplication by reference. The teeth were thus comprised of acrylicplastic and without the use of mechanical locking means, a good chemicalbond is preferred to assure a permanent securement of the teeth to thedenture baseplate.

The full arch set of upper teeth was placed in position adjacent to thedenture baseplate in a measured precise position measured in relation tothe dental model of the upper jaw prior to the forming of the denturebaseplate thereon. The position simulates a functional and aestheticalignment of the full arch set of teeth relative to the denturebaseplate. This was done by using the guiding indicia on the occlusiontable 114 as described with respect to FIG. 37 earlier.

The upper dental model was then reinstalled in the articulator with theupper dental baseplate in position on it with the release coat betweenthe denture baseplate and the model. The rod-shaped VLC putty was usedas a tacking putty to initially secure the denture baseplate and teethtogether. The tacking quantity of putty was initially applied to thedenture baseplate in the rod shape around the ridge of the baseplate andcurved around in the general configuration of the full arch set ofteeth. The tacking quantity of putty is such that it will later becovered up and thus need not in itself offer a fully aestheticappearance when placed, although it is preferable to and was in factinitially shaped by hand and flattened out against the denture baseplatewhere it contacts or engages the baseplate.

With the full arch set of teeth in their adjacent position as previouslydescribed, the portion of the articulator mounting the dental modelhaving the shaped denture baseplate engaged thereon was hingedly closedas previously described with respect to FIG. 38. The tacking quantity ofputty was trapped between the closing baseplate and the teeth. The teethwere thereby engaged with the tacking putty.

The dental baseplate will be understood to have been engaged with thefull arch set of teeth with the teeth maintained in their precisemeasured position when the model was returned to its previouslyestablished precise position. The teeth were maintained in position bybeing held by hand against adjustable positioning member 166.

The tacking putty was then hardened by actinic visible light to rigidlyattach and secure the full arch set of teeth to the denture baseplateproviding the positioning of the full arch set of teeth for receipt ofthe gum simulating putty which corresponds to the previously referred toadjacent position. This hardening was by curing through the engagementof the putty with visible actinic light for two minutes in the mannerpreviously described respecting the curing of the upper denturebaseplate. In this manner the full arch set of teeth is positioned.

Next the facial and lingual aspects of the denture were finished withadditional rod putty. To do this the upper jaw model was again securedto the upper articulator bow member 86 via the securing pin 90 and thearticulator was opened and turned around and tipped back on its rearedge stand surface 100 for ease of working. The putty, which was of thesame visible light curable composition as that used for the baseplateand the tacking putty, was molded about the teeth at their gingival endsto simulate gum tissue. The gum simulating application of putty was byhand using instruments of the type commonly employed for shaping wax tosimulate gum tissue in a dental lab. The material worked well usingstandard techniques. Material was also added to the back of the fullarch set of teeth to merge the gingival ends of the teeth with thedenture baseplate more aesthetically and to provide a better feel forthe denture wearer.

Thereafter the upper jaw model with the upper denture attached wasremoved from the articulator by removal of securing pin 90 and an oxygenbarrier layer of the composition of surface cure promoter portion of thetwo part separator layer previously described was applied as a topcoating over the exposed surfaces of the putty of the gum simulatingportions and the other portions of the denture and the denture was curedwith visible light for four minutes in the manner described above. Thishardened the putty molded about the teeth at their gingival ends bysubjecting the putty to actinic visible light engagement.

The upper and the lower jaw models were then secured in precise positionin the articulator via pins 90 and 74 respectively, with the articulatorin the open position as shown in FIG. 36 but with the occlusion mountingtable 114 removed as illustrated in FIG. 39. The lower jaw position wasestablished earlier, related fixedly to the position of the upper jawmodel, in the position it is to be in when the upper denture baseplateis fully closed with the full arch set of upper teeth on the occlusiontable 114.

The molding surfaces of the lower jaw model were coated with the sametwo-part release coat system as was used on the upper model and in thesame manner. A sheet of the same visible light curable polymericcomposition used to make the upper denture baseplate was conformed tothe desired shape on the lower jaw model over the release coat in themanner practiced with the upper denture preparation. The model with theformed denture baseplate thereon was then removed from the articulatorand the polymeric composition was hardened by engaging it with visiblelight in the manner described respecting the upper denture baseplate.The lower model with the thus formed lower denture baseplate was thenresecured in the articulator with pin 74.

The articulator was then closed, bringing the upper denture just abovethe lower denture baseplate. Next the lower full arch set of teeth wasaligned in occlusion with the upper full arch set of teeth after theupper full arch set of teeth which have already been set in theirprecise position. If the lower set of teeth cannot initially be fullyoccluded with the upper set of teeth and aligned with the lower denturebaseplate for proper mounting, necessary adjustments in accordance withusual dental prosthetic techniques are used to adjust the occludedclosing in proper relation with the upper denture in its earlierestablished precise position. Some grinding of the ridgelaps and otheradjustments may be needed to obtain proper fit. In the specific sequenceof operation here being described, this was required.

The full arch set of lower teeth were of the same composition as theupper teeth and were prepared for attachment to the lower denturebaseplate by roughening and applying a bonding agent in the same manneras the upper full arch set of teeth.

Next a tacking quantity of the same rod-shaped putty used with respectto the upper denture was curved around in the general configuration ofthe intended lower full arch set of teeth. The articulator was thenswung partially closed pressing the lower full arch set of teeth intothe tacking putty on the lower denture baseplate while the full arch setof teeth were held in occlusion with the upper full arch set of teeth byhand.

Thereafter, the lower model with the lower denture baseplate thereonwith the teeth attached was removed and the tacking putty was hardenedwith visible light in the manner described respecting the upper dentureconstruction. The tacking putty was hardened in engagement with thelower full arch set of teeth.

The lower model was then resecured in the articulator with pin 74 andthe struts were removed as described respecting the upper denture. Thismay also be done while the model is free from the articulator. Next, thearticulator was tipped back on stand surface 100 and visible lightcurable putty was molded about the gingival ends of the teeth in thesame general manner described respecting the preparation of the upperdenture.

Then the lower model with attached denture was removed from thearticulator by releasing pin 74 and the exposed surfaces were coatedwith an oxygen barrier layer as described respecting the upper denturepreparation. Then, the visible light curable composition putty aroundthe gingival ends of the teeth simulating the gum tissue and at the backof the arch at the gingival ends was hardened with visible light asdescribed respecting the upper dentures preparation.

As a final procedure, the lower denture still mounted on the model isreturned to the articulator and the thumb screws 104 are backed out andthe articulator is used to mill the occlusal surfaces to enhance betterocclusion. An abrasive of the type usually used for milling of plasticartificial teeth is used and the upper bow is then moved back and forthand from side to side under hand pressure.

After the milling procedure, the upper and lower dentures were removedfrom their respective stone models using substantially conventionaltechniques which involved sectioning the stone models with a saw andpulling the pieces of the stone models away from the respectivedentures. The borders of the upper and the lower dentures were thentrimmed and any needed smoothing of imperfections was carried out as isconventional. Then, the entire denture surfaces were polished inconventional manner using pumice, rag wheels, and buffing compounds. Thesurfaces were then washed with tap water and dried with a paper toweland found to be dry, shiny, and tack free. The dentures were thenclinically fitted by placing them in a patient's mouth and found to givean excellent and true fit and to have a good, aesthetic appearance andto provide good function both in mastication of food and speech.

In accordance with the principles of the invention, a full arch set ofartificial teeth comprises in integral combination, a pair of similarcentral teeth each respectively flanked on one side by a lateral tooth,the lateral teeth each being flanked on one side by a canine tooth, andeach canine tooth being flanked at one side by a set of four posteriorteeth each comprising a pair of bicuspid teeth next to the canine teeth,and a pair of molar teeth extending from one end of each pair ofbicuspid teeth. In some situations, it may be possible to vary the exactanatomy of the full arch set of teeth described so long as the aestheticvalue of a full arch set of teeth is achieved. Of course, in this day ofnovelty items, variations to obtain special effects are not to beunderstood as departing from the true contribution of the presentinvention.

While the present invention has been described with the overall genericinvention highlighted, it will be obvious to those skilled in the artthat the species of the invention have wide application. Also, while inaccordance with the present statutes, what is at present considered tobe the preferred embodiment of the invention has been described, it willbe obvious to those skilled in the art that numerous changes andmodifications may be made therein without departing from the invention,and it is therefore aimed in the appended claims to cover all suchequivalent variations as fall within the true spirit and scope of theinvention.

We claim:
 1. A plurality of integral artificial teeth comprising atleast one anterior tooth having its labial face disposed at an anglefrom the vertical of about 0° to 10° sloping backward from the incisaledge for at least about 70 percent of the length of the tooth, and atleast one posterior tooth having its buccal face disposed at an anglefrom the vertical of about 1° to about 10° sloping inward from thegingival edge for at least about 90 percent of the length of the tooth.2. The plurality of integral teeth according to claim 1 wherein saidanterior tooth is a canine tooth.
 3. The plurality of integral teeth ofclaim 1 wherein a planar member can be laid against the said buccal faceof said posterior tooth and extend from the occlusal edge to thegingival edge of said tooth and not being out of contact with said toothby more than 10° for 90 percent of the height of said tooth.
 4. Theplurality of integral teeth of claim 1 wherein there are at least twojuxtapositioned anterior teeth and at least two juxtapositionedposterior teeth.